MIN586: Metal Forming

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Dr. Shamik Basak
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Assistant Professor
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Department of Mechanical and Industrial Engineering
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Indian Institute of Technology Roorkee, India

Email id: [email protected]

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 MIN586: Metal forming

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Credit 4 : L-3, T-1, P-0

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Lecture sessions:

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•Tuesday: 10 am - 10.55 am

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•Thursday: 10 am - 10.55 am
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•Friday: 10 am - 10.55 am
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Tutorial session:

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•Tuesday: 4.05 pm - 5.00 pm

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Additional Saturday classes: IIT

21st Aug, 4th , 18th Sept, 23rd Oct.

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Grading:

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• Assignments, short exams, quizzes (CWS)

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(weightage 25%)

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• Midterm exam (MTE)
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(weightage 25%)

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• End term exam (ETE)

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(weightage 50%)
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IIT
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 Reference books

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1. “Plasticity of Mechanical Engineers” by W.Jhonson and

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P.B.Meller, Van Nostrand.

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2. “Manufacturing Science” by A.Ghosh and A.K.Mallik.
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3. “Metal Forming Mechanics and Metallurgy” by W.F.Hosford
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and R.M.Caddll.

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4. “The Mathematical Theory of Plasticity” by R.Hill.

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IIT
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 Material processing

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• Casting- Expendable and multiple use mold

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• Forming- bulk forming, sheet forming, powder metal
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• Joining- welding, brazing, soldering and mechanical joining

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• Metal Cutting- Mechanical machining and nontraditional
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machining IIT
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 What is Forming?

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• Forming is a mechanical process used in manufacturing industries wherein

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materials (mostly metals) undergo plastic deformations and acquire required

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shapes and sizes by application of suitable stresses such as compression,

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shear and tension.
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• In the forming process, no material is removed; it is completely displaced and

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deformed into the required shape.

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• The weight of the material is same before and after forming operation.
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 Forming

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Powder
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Metal

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Forming Forming
Forming

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• Deep drawing • Powder forging
• Rolling
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• Stretch forming • Powder extrusion
• Forging

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• Bending • Powder injection
• Extrusion

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• Shearing molding etc.
• Drawing etc.

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Apart from these conventional forming processes also non-conventional of high energy rate
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forming processes (HERF) are also there

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Different Forming Processes

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Forming Applications

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 Applications of Deep Drawn Products in Real life

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Aerospace components Cans and package utensils

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Household utensils

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IIT
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Beverage cans Automobile components

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 Forming Applications

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Automotive assembly line for producing

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auto-body.

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Companies interested for sheet forming

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products

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• TATA motors, steels
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• Honda, Ford, Toyota IIT

• Audi, Benz, Hyundai

• Tesla

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Exploded view of various automotive components

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 Classification of metal forming processes

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Compressive forming processes

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Rolling

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Open die forging

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Closed die forging Extrusion
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IIT
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 Classification of metal forming processes

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Tensile forming processes

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Stretch forming Hydro forming
(Erichsen cup test)
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 Classification of metal forming processes

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Combined Tensile and Compressive forming processes

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Wire drawing Tube drawing

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Cup drawing

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IIT
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Deep drawn products

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 Classification of metal forming processes

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Forming by bending

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 Classification of metal forming processes

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Forming by shearing

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 De Dr
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Thank you!

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